Roll forming is one of the most versatile and productive manufacturing methods ever devised for metal. 
Every house, car, office and factory contains numerous roll formed metal components, yet despite the enormous quantities of metal worked in this way, new markets for roll formed products are still emerging, and the true potential of the process is only now starting to be realised.
Roll forming, a continuous, high volume process involves passing flat strip in coil through a series of contoured rolls, progressively forming the metal to achieve sections of virtually any profile. The process maintains a high degree of consistency and accuracy, producing to any desired length from a wide range of materials.
Already new computer software is transforming the cold rolled sections industry, speeding up and making product development more effective. Further developments will see predictive software help designers work even more closely with potential customers and evaluate alternative cold rolled section designs on screen. This means that the role of product innovation in the cold rolled sections industry will become even more apparent in the 21st century.
We have developed in house computer simulation tools that determine the strain, forming angle, spring back, shear and geodesic movement during the cold roll forming process. These parameters can be used to develop contour plots which show how the material flows through the rolls and illustrates the levels of strain as the shape of the profile is progressively formed.
The use of such tools allows the designer to optimise the number of stations within the cold rolled forming process; therefore reducing design and roll tool manufacture time. This technology together with the designers knowledge and experience enables us to develop and produce more intricate but cost effective solutions.
One major technical breakthrough in the development of roll forming by Hadley is the UltraSTEEL™ process which can be applied to virtually any cold rolled formed section or product.
UltraSTEEL™ is an internationally patented method of altering the surface characteristics of roll formed steel in strip which, in addition to conferring an attractive finish, also provides equal strength from lighter gauge material, resulting in a more cost-effective end product.
An almost limitless variety of cross-sections can be produced, subject to the ingenuity of the roll designer. As well as being a science, his job is also a creative art: he needs experience and a feel for the process to guide him. Advanced computer-aided design and manufacturing systems are used, not to eliminate the designer's craft skills but to multiply them and make them accessible to others.
Modern technology combines with traditional craftsmanship and decades of invaluable experience to improve already high standards of quality, and make roll forming even more versatile, dependable, productive and efficient.
